Method for manufacturing a cable component

Abstract

An embodiment of a method for manufacturing a cable component includes providing at least a pair of shaped wire members, passing the wire members through at least one shaped roller set, providing at least one cable portion, placing the wire members over the cable portion and running the wire members and cable portion through an assembly roller to form a subassembly, and attaching a fixing element to the subassembly to secure the wire members and cable portion to complete the cable component.

What is claimed is: 
     
       1. A method for manufacturing a cable component, comprising:
 providing a pair of shaped wire members, wherein the pair of shaped wire members have a shape, allowing the pair of shaped wire members to form a metallic conductor with an opening therethrough when the pair of shaped wire members are engaged with one another; 
 holding the pair of shaped wire members with at least one shaped roller set, wherein the at least one shaped roller set is configured to conform to the outer surfaces of the pair of shaped wire members, and wherein the at least one shaped roller set maintains the pair of shaped wire members in an orientation for placement about a cable portion, wherein the cable portion is enclosed in the opening formed through the engaged pair of shaped wire members; 
 placing the pair of shaped wire members about the cable portion and running the wire members and cable portion through an assembly roller to form a core subassembly, wherein the core subassembly comprises the cable portion having the pair of shaped wire members engaged thereabout, wherein the pair of shaped wire members are conductors and protect the cable portion; and 
 attaching a fixing element to the core subassembly to secure the pair of shaped wire members and cable portion to complete the cable component. 
 
     
     
       2. The method of  claim 1  wherein passing each of the pair of shaped wire members through at least one shaped roller set places the wire members in a proper orientation for running through the assembly roller. 
     
     
       3. The method of  claim 1  wherein the at least one shaped roller set comprises a roller having a concave surface and a roller having a convex surface, each of the surfaces configured to engage with an outer surface of the pair of shaped metallic wire members. 
     
     
       4. The method of  claim 1  wherein providing the cable portion comprises providing a one of an optical fiber and a metallic conductor. 
     
     
       5. The method of  claim 4  wherein the cable portion comprises a polymeric layer disposed on an exterior surface of the at least one cable portion. 
     
     
       6. The method of  claim 4  further comprising extruding a polymer layer over an exterior surface of the cable portion. 
     
     
       7. The method of  claim 1  wherein the assembly roller comprises rollers comprising a concave surface for cooperatively engaging an exterior surface of the at least a pair of wire members. 
     
     
       8. The method of  claim 1  wherein attaching comprises extruding a layer of polymer over the core subassembly. 
     
     
       9. The method of  claim 8  further comprising passing the core subassembly through a heat source to modify surfaces of the pair of shaped metallic wire members prior to extruding. 
     
     
       10. The method of  claim 9  further comprising extruding a tie layer over the modified pair of shaped wire members prior to extruding. 
     
     
       11. The method of  claim 8  further comprising passing the core subassembly through a water bath after extruding. 
     
     
       12. The method of  claim 1  wherein attaching comprises wrapping a layer of tape over the core subassembly. 
     
     
       13. The method of  claim 1  wherein attaching comprises cabling a layer of serve wire over the core subassembly. 
     
     
       14. The method of  claim 1  wherein the cable component comprises a one of a slickline cable, a component of a wireline cable, and a component of a seismic cable. 
     
     
       15. The method of  claim 14  further comprising deploying the cable component into a wellbore and performing at least one wellbore operation.